EP0635079B1 - Fire-resistant roofing and cladding material - Google Patents

Abstract

Composite roofing and cladding material comprising: (A) a bitumen-coated cellulose base material (1) combined with (B) a modified or unmodified, bitumen-coated, surfaced and impregnated glass mat to form a layer, which further includes on its outer side at least one material (3) selected from the group consisting of mineral granulates, slate flakes and non-foamed silicate lamellates, while the base material bitumen and/or cellulose substrate is further filled with at least one mineral or synthetic powder. An alternative embodiment includes a reinforcing element (4) inserted between materials (1) and (2). Application in fire-resistant roofing and cladding materials.

Description

The present invention relates to materials for roofing and siding; it concerns more particularly a fire-resistant material for roofing and cladding, as well as a process for obtaining it.

We know materials for roofing and cladding, in corrugated and light sheets, essentially consisting of cellulose fibers saturated with bitumen or tar. Due to their composition, these elements of roofing are, in some cases, flammable.

We also know from document DE-A-1 078 990 roofing sheets with a lifetime improved, combining a support plate and a layer of coating, the latter being essentially composed bitumen and poly (vinyl chloride), poly (chloride vinylidene) or copolymers thereof, as well as sand or gravel. Improving resistance weather and sunlight is the goal fire resistance is not treated.

Document US-A-2 893 889 describes a material for fiber-based blanket comprising a layer basic fibrous and essentially compound coating of a mixture of glass filaments of critical dimensions and impregnation bitumen. It is specified that, for the fire resistance, glass filaments must have a 0.5 to 4 micrometers in diameter and must represent plus approximately 5% by weight of the asphalt-filament assembly.

Document FR-A-2 372 927 describes a method of manufacturing bituminous corrugated sheets with difficulty fuel, in which we sink, on the surface of the raw cardboard still wet, solution or suspension aqueous containing ammonium salts, a boron compound, an antimony compound, a silicate, a compound organic bromine, as well as poly (vinyl chloride). The plate thus composed is then formed, dried and impregnated with hot bitumen.

Document EP-A-0 209 712 describes a plate for roofing consisting of a sheet of fibers treated for be permeable to water vapor, but impermeable to water, by adding a mass to both sides impregnation comprising bitumen and paraffin.

There was therefore a need to make resistant fire of materials of the above type.

After extensive research, we now have unexpectedly found that constitutes a material of this type with excellent resistance to fire and flames an essentially composite material of a combination of a cellulose base material bituminous with a glass veil impregnated and surfaced with using modified bitumen coated on its external face at least one subject chosen from the group consisting of mineral granules, slate flakes and unexpanded laminated silicates, while bitumen and / or the cellulosic support of the base material is additionally loaded with at least one mineral powder or synthetic, and that said material further comprises on the underside from the bitaminated cellulosic support a layer of thermosetting resin.

It also appeared that the material according to the invention has the additional advantages of being a stable, light covering and cladding material, aesthetic and having resistance to aging and the action of UV radiation greatly improved by compared to existing roofs and cladding.

The present invention has for first object a composite material for roofing and cladding according to claim 1.

Said glass veil preferably consists fibers of a few micrometers, advantageously about 2 to 4 micrometers in diameter and a few millimeters long. It advantageously represents 9-12% by weight of the bitumen, modified or not, of said screed.

The invention will be better understood with reference to the description below and the attached drawings, which aim to illustrate it more concretely, but do not limit it not at all.

Fig. 1 représente une vue en coupe transversale schématique partielle d'un matériau ondulé selon l'invention avec des ondes sinusoïdales régulières;

Fig. 2 représente une vue en coupe transversale schématique partielle d'un matériau ondulé selon l'invention avec des ondes respectivement haute et basse de rayons de courbure différents; et

Fig. 3 représente une vue en coupe transversale schématique partielle d'un matériau ondulé selon l'invention avec des ondes respectivement haute et basse de rayons de courbure différents, comme dans la figure 2, mais dans lequel est introduite longitudinalement sur les ondulations supérieures une pièce métallique en forme de cornière.

In the attached drawing sheet:

Fig. 1 shows a partial schematic cross-sectional view of a corrugated material according to the invention with regular sine waves;

Fig. 2 shows a partial schematic cross-sectional view of a corrugated material according to the invention with respectively high and low waves of different radii of curvature; and

Fig. 3 shows a partial schematic cross-sectional view of a corrugated material according to the invention with respectively high and low waves of different radii of curvature, as in FIG. 2, but in which a metal part is introduced longitudinally on the upper corrugations shaped like an angle iron.

It should be noted that a composite material having any other transverse or even flat profile fits also in the context of the present invention.

As shown in Figure 1, the composite material for roofing and cladding according to the invention comprises a bituminous cellulose base material 1, a veil of glass impregnated and surfaced with modified bitumen, so as to form a yoke 2, which further bears on its face external coating of at least one chosen material 3 in the group consisting of mineral granules, slate flakes and non-laminated silicates expanded. As indicated above, the composite material according to the invention further comprises, as charge of the bitumen and / or the cellulosic support of the base material, a mineral or synthetic powder, not shown on the figures.

In practice, the material thus composed preferably consists, but without being limiting, in corrugated sheets of approximately 2 m x 1 m, with waves having a pitch P of about 96 mm from a vertex to the vertex contiguous, for a depth of undulations of approximately 35 at 50 mm, with a preference for heights h undulations of 35-50 mm and overall widths H of the material from the top of a wave superior to the top of the neighboring hollow wave between approximately 45 and 60 mm.

Waves are also defined by their angle of curvature, which can be the same for high and low ripples, for example R ₁ = about 16 mm, or a different radius for high ripples, such as a smaller radius R ₂ = approximately 5 mm (see figures).

Advantageously, an end lateral wave is reserved, i.e. not covered, to facilitate its overlap by a wave itself covered with the neighboring plate.

The aforementioned charge of bitumen and / or material cellulosic consists of powdered poly (vinyl chlorides) or poly (vinyl chlorides) vinylidene) doped and / or alumina hydrate, hydrate magnesium, antimony trioxide or paraffin chlorinated.

According to a preferred form of implementation, the powder added as filler for bitumen and / or material cellulosic is a fine synthetic powder of PVC or PVDC stabilized with lead and doped with antimony oxide or a mineral powder of alumina or magnesium hydrate.

The composite assembly thus formed is suitable for meet the T / 30/1 test defined by CSTB (Center Building Scientific and Technical, 4 avenue du Recteur Poincaré, Paris, France).

Bitumen for impregnating the cellulosic support is preferably a road bitumen, but can also be all or part of any other bitumen quality, such as distillation bitumen direct or oxidized bitumen.

The layer of thermosetting resin under the support bituminized cellulosic, gives said cellulosic support a improved dimensional stability in case of variation of humidity level of this support. For example no limitative, said resin is melamine, which has proven to significantly reduce the impact on the elongation of the cellulose and its resistance to bending of the celllulose water uptake, even impregnated with bitumen.

According to another variant, the material according to the invention also includes a reinforcing element 4 (see figure 3) inserted between parts 1 and 2. In an embodiment of this variant constituting the best mode of implementing the invention according to the knowledge acquired to date, material 1 has a developing wave-shaped cross section substantially sinusoidal and the reinforcing element aforesaid in the form of a metallic angle iron each or at least several of the upper waves. Of plus, at least in such a variant, it appeared advantageous that the higher waves have a radius of minimum curvature or at least less than that of waves lower.

Said reinforcing element 4, in particular said metal angle, can be made of any metal or suitable metal alloy, such as steel, stainless steel, galvanized steel, lacquered steel, aluminum and / or copper.

Preference goes to metal elements 4 narrow angle type, capping substantially throughout their length the upper waves of material 1, which thus allow it to be evacuated through the part cellulose of the composite roofing material or cladding water vapor likely to pass through said material, thereby helping to maintain humidity acceptable, without damage to the support.

In this preferred variant according to the invention, said reinforcing element can advantageously be inserted between the vertices of the base material waves and the flexible bituminous screed which covers it. he To ensure the cohesion of the whole, one effective bonding, within the reach of the skilled person. In in practice, these reinforcing elements are found embedded in the surfacing bitumen and are thus protected against corrosion by the material 2.

The most advantageous form of implementation described above gives the material mechanical strength - flexural strength - improved, better lift between breakdowns and better visual appearance.

In practice, the joining of the parts 1 and 2 between them is done by simple intimate bonding, hot.

For better material efficiency according to the invention the impregnation and surfacing bitumen glass veil (B), with which it forms a yoke, is preference chosen from distillation bitumens direct modified by the addition of an elastomer, in particular an elastomer of atactic polypropylene, styrene butadiene or natural rubber. The screed meeting this advantageous variant has proven have remarkable resistance to aging, good flexibility and high stickiness, ensuring the perfect hold of the granules or flakes on the surface and the intimate connection with the support made of cellulosic material.

The yoke 2 according to the invention may also include, optional other active charges capable of releasing water vapor under the action of the heat produced by an outbreak, such as for example hydrate alumina, preventing the spread of flames.

Another example of such an active charge for screed 2 is the phosphogypsum hemihydrate, of crude formula CaSO ₄ .1 / 2H ₂ O, which is able to withstand the introduction into hot bitumen (at about 180 ° C) without cause too much bubbling and surface bubbles. Thus introduced into the bitumen of the screed 2, this active charge releases water and then constitutes a mass such as glass, opposing a fire barrier.

The presence of flaky silicate flakes unexpanded also contributes, by the formation of a a kind of "meringue" on the surface under the effect of a fire, protection of the substrate.

The classic components of the material according to the invention are chosen from those which are known to those skilled in the art for such use or uses alike. Also the respective proportions of different components of materials and fillers or others additives can be chosen on a case-by-case basis by humans of the profession, depending on the objectives and on the basis routine testing, if necessary.

a) on réalise un support cellulosique 1, de préférence ondulé ou profilé d'une autre manière, et on le charge avec au moins une poudre minérale ou synthétique choisie parmi les poudres de poly(chlorures de vinyle) ou de poly(chlorures de vinylidène) dopés et/ou d'hydrate d'alumine, d'hydrate de magnésium, de trioxyde d'antimoine ou de paraffine chlorée, tandis que ladite charge représente environ 5 à 20%, de préférence environ 10 à 16%, en poids/poids du support cellulosique bituminé,

(b) on imprègne à coeur le support cellulosique susdit avec du bitume routier,

(c) on applique, de préférence par collage intime à chaud, sur une face de la plaque de matériau imprégné obtenue, une charge bitumineuse 2 armée d'un voile de fibres de verre, revêtue sur la face opposée d'au moins une matière 3 choisie dans le groupe composé des granulés minéraux, de préférence colorés, des paillettes d'ardoise et des silicates feuilletés non expansés, et on applique en outre en sous-face dudit support une résine thermodurcissable.

The invention also relates to a process for the production of such a material, in which:

a) a cellulosic support 1 is produced, preferably corrugated or otherwise shaped, and it is loaded with at least one mineral or synthetic powder chosen from powders of poly (vinyl chlorides) or poly (vinylidene chlorides) ) doped and / or alumina hydrate, magnesium hydrate, antimony trioxide or chlorinated paraffin, while said charge represents approximately 5 to 20%, preferably approximately 10 to 16%, by weight / weight of the bituminized cellulosic support,

(b) the above-mentioned cellulosic support is impregnated with road bitumen,

(c) applying, preferably by intimate hot gluing, to one face of the plate of impregnated material obtained, a bituminous filler 2 armed with a veil of glass fibers, coated on the opposite face with at least one material 3 chosen from the group consisting of mineral granules, preferably colored, slate flakes and non-expanded laminated silicates, and a thermosetting resin is also applied on the underside of said support.

Alternatively, the subject of the invention is such a process, also including the insertion between the base material 1 and screed 2 of an element of reinforcement 4 described in more detail above. This variant is advantageous because it leads to placing without damage, between the two waterproof bituminous materials 1 and 2 intended to be assembled, reinforcing elements, which can be very thin and light and which, between the cellulosic element and also the bituminous screed, are perfectly protected against corrosion and can considerably increase the flexural strength of the composite material. So the doubling of the quadratic moment of inertia and increasing the wave height of a material wavy commposite, i.e. the distance from neutral fiber, increase the use distance between the supports and supports, as well as the load, especially snow, or resistance to tearing.

It is even possible to predict an overflow of reinforcing elements at the ends of the plates unitary in an appropriate way to allow that they also serve as connecting elements between two or more of two plates.

By way of nonlimiting example, it is possible to use a bituminized glass fiber screed, comprising a small addition of atactic polypropylene in the impregnation bitumen and covered on its surface remaining visible with granules having the desired color or better expanded vermiculite flakes. This screed of appropriate size is applied, lukewarm, in the direction of the waves (one wave of which is left reserved for its covering by a neighboring plate, when in use) on a sheet of bituminized cardboard which was made to exude just before to bring it into contact with the above-mentioned screed, preformed exactly at the pitch and at the depth of the undulations, of radius R ₁ and / or R ₂ , of the plate to be covered. A very light calendering, on the screed, completes the connection between plate and screed. Furthermore, a layer of melamine is applied to the underside of the plate, before or after the above-mentioned process, preferably at a rate of approximately 60 g for a plate surface of approximately 2 m ² .

For the variant using elements metallic 4 as described above, it suffices to insert these elements between plate and yoke so before applying the screed to the plate as indicated above. In practice we use to do this light metal blades in the form of a square, which place astride the summits of the waves or angles at cover with the base plate.

The existing differences between the coefficients respective thermal expansion of the material cellulosic and this metallic material does not constitute not a discomfort, because the metal element is linked elastically to bitumens, which accept expansions differentials. It is the same for the expansion or retraction of the cellulose from the plate base according to its degree of humidity: bitumen elastic accepts differences in elongation or shrinkage that may occur between cellulose sensitive to moisture and moisture-insensitive metal.

The above active charges, in particular in the form fine PVC powder stabilized with lead and doped with antimony and / or alumina hydrate, can replace totally or partially the traditional charges, such as calcium carbonate, permeating conventionally a bituminized cellulosic material for roofing and cladding.

Although each of the elements entering the combination described above contributes to fire resistance appropriate to the overall material, none of them taken in isolation cannot be considered sufficient for this purpose. The material according to the invention is proved to present a particular synergy in this respect, which is that fire resistance involves several responses to various constraints. This is how the non-transmission of calories created by the household of fire is brought by certain products, more than by others. The creation of an unfavorable atmosphere combustion is another positive factor in resistance fire; in this respect, the glass veil creates a real fence. The underside treatment with a resin particular constitutes a barrier to the flame spread under the roofing plate.

The material according to the invention can be used works according to known techniques, on the roof and cladding, and more generally in all applications for which these plate materials fill the function of fire resistant materials.

The invention therefore also relates to the use of these materials for the realization of fire resistant roofing or cladding.

Claims (13)

1. A composite roofing and cladding material, essentially composed of a combination of:

   (A) a bitumen-coated cellulose base material (1)
   comprising

   (B) a glass mat which is impregnated and surface-treated by means of
   a bitumen or modified bitumen so as to form a coating (2),
   and comprising in addition on its outer face at least one material (3) selected from the group comprising mineral granules, slate flakes and unexpanded layer silicates,

   characterised in that the bitumen and/or the cellulose support of the base material is filled in addition with at least one mineral or synthetic powder selected from doped poly(vinyl chloride) or poly(vinylidene chloride) powders, and/or hydrated alumina, hydrated magnesia, antimony trioxide or chlorinated paraffin wax, in a proportion (weight/weight) of about 5 to 20 %, preferably about 10 to 16 %, of the bitumen-coated cellulose support,
   and that said material additionally comprises a layer of thermosetting resin on the underside of the bitumen-coated cellulose support (1).
2. A material according to claim 1, characterised in that the powder which is added as a filler to the bitumen and/or to the cellulose material is a fine synthetic PVC powder which is stabilised with lead and which is doped with antimony oxide.
3. A material according to either one of claims 1 or 2, characterised in that the bitumen used for impregnating and surface-treating the glass mat, with which it forms a coating (2), is selected from direct distillation bitumens which are modified by the addition of an elastomer.
4. A material according to claim 3, characterised in that the elastomer is an elastomer of atactic polypropylene, of styrene-butadiene or of natural rubber.
5. A material according to any one of claims 1 to 4, characterised that in that it comprises active fillers which are suitable for the evolution of water vapour under the action of the heat produced by a source of heat.
6. A material according to claim 5, characterised in that said active fillers are hydrated alumina.
7. A material according to any one of claims 1 to 6, characterised in that it additionally comprises a metal reinforcing element (4) between the panel (1) and the coating (2).
8. A material according to claim 7, characterised in that the material (1) has a cross-section in the form of corrugations which extend substantially sinusoidally, and the reinforcing element (4) is a metal angle which covers at least a plurality of the upper corrugations of said material (1).
9. A material according to claim 8, characterised in that the upper corrugations of the material (1) have a radius of curvature which is less than that of the lower corrugations.
10. A process for producing a composite roofing and cladding material, characterised in that:

    a) a cellulose support (1) is produced, which is preferably corrugated or contoured in another manner, and is filled with at least one mineral or synthetic powder selected from doped poly(vinyl chloride) or poly(vinylidene chloride) powders, and/or hydrated alumina, hydrated magnesia, antimony trioxide or chlorinated paraffin wax, whilst said filler represents about 5 to 20 %, preferably about 10 to 16 % (weight/weight), of the bitumen-coated cellulose support,

    b) the aforementioned cellulose support is impregnated throughout with road bitumen,

    c) a bituminous coating (2) is applied, preferably by hot, intimate adhesive bonding, to one face of the impregnated panel of material obtained, which bituminous coating is reinforced with a glass fibre mat, and is coated on its opposite face with at least one material (3) selected from the group comprising mineral granules, which are preferably coloured, slate flakes and unexpanded layer silicates, and a thermosetting resin is additionally applied to the underside of said support.
11. A process according to claim 10, characterised in that said road bitumen is previously filled with at least one mineral or synthetic powder selected from doped poly(vinyl chloride) or poly(vinylidene chloride) powders, and/or hydrated alumina, hydrated magnesia, antimony trioxide or chlorinated paraffin wax.
12. A process according to claim 10, characterised in that metal elements (4) are additionally intercalated between the panel (1) and the coating (2).
13. Use of a material according to any one of claims 1 to 9 for producing fire-resistant roofing or cladding panels.

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